Protective helmet and support portion for said protective helmet

ABSTRACT

The invention relates to a protective helmet which has an outer shell and an inner layer. The protective helmet according to the invention is characterized in that the inner layer has a plurality of pads. The protective helmet according to the invention provides a slimmer visual appearance and an improved fit.

The invention relates to a protective helmet, which includes an outer shell and an inner layer.

Such protective helmets are very well known and find application, for instance, in sport, such as when skiing or cycling. The invention is particularly directed (but not limited) to a bicycle helmet.

The outer shell of conventional helmets is generally relatively rigid. It serves to protect the (softer) inner layer within it The inner layer consists, for instance, of EPS, an expanded polystyrol hard foam, and serves, in particular, to cushion the impact energy in the event of a crash. An adjustable support ring can additionally be provided, with which it is possible to adapt the helmet to the size of one's head.

It is necessary for a good protective effect that, on the one hand, the inner layer exhibits adequate cushioning properties. This is ensured in part by the selection of the material and in part by the thickness of the inner layer. It is necessary for an optimal protective effect, on the other hand, that the inner layer engages the head of the helmet wearer well, that is to say over a large area.

The construction described above has proved to be satisfactory in many areas for many years. It has, however, been found that, on the one hand, the known helmets are of quite broad construction and thus frequently have a clumsy appearance and that, on the other hand, the protective effect can be further improved by better fitting shapes.

Starting from the known prior art, it is the object of the invention to provide a helmet which, on the one hand, has a slim visual appearance and, on the other hand, has an improved fit by comparison with known helmets.

In order to solve this object, the protective helmet referred to above is characterised in accordance with the invention in that the inner layer includes a plurality of pads.

The pads ensure an optimal fit of the helmet on the head of the user. At the same time, the pads ensure a good cushioning effect in the event of a crash of the helmet wearer and surprisingly also if the pads are connected directly to the outer shell of the protective helmet, that is to say without a further cushioning layer, as is proposed in an embodiment of the invention.

In an important embodiment of the invention it is proposed that the inner layer acts substantially exclusively as the cushioning layer. Reference is made in this connection to the fact that other components of the protective helmet in accordance with the invention, for instance the outer shell or a functional and/or decorative layer (as will be described in detail below) also contribute to the cushioning effect since these components have elastic properties, at least to a certain extent. This is supposed to be taken account of by the wording “substantially exclusively”. However, every protective helmet has a layer which is intended to provide a cushioning effect. In known helmets, this layer generally comprises hard foam. This cushioning layer is to be constituted in the context of the embodiment of the invention substantially exclusively by the pads or the inner layer including the pads.

It is exclusively the pads which preferably define a contact surface for the head of the wearer. Thus when wearing the protective helmet, it is exclusively the pads which come into contact with the head. The pads thus take over the fitting and cushioning function.

It is regarded as particularly advantageous if a plurality of pads are provided, preferably at least ten pads, particularly at least 15 pads. As a result of a plurality of pads, the protective helmet is, on the one hand, particularly adaptable and, on the other hand, the shape of the helmet can be maintained particularly slim by using a plurality of pads. This has not only optical advantages but also considerable advantages as regards the manageability of the helmet. Furthermore, the individual pads permit good ventilation of the head, which ensures excellent wearing comfort.

Tests have shown that a substantially truncated pylon-shape of the pads is particularly advantageous. The free end region is of convex shape. The pads preferably have a round cross-section. It is expected that such a pad shape results in a particularly good fit of the protective helmet on the head of the helmet wearer. At the same time, a round cross-sectional shape permits an advantageous distribution of the pads.

Alternatively, the pads are of part-spherical shape, particularly hemispherical shape. Angular, for instance rectangular or square pad shapes are also possible within the context of the abstract inventive concept. It is considered to be convenient if the pads have a certain convexity in order that the inner layer of the protective helmet comes into engagement with the head of the helmet wearer as much as possible over its entire contour.

The pads are filled with small beads, which are movable with respect to one another. Tests have shown that the cushioning performance of such pads is significantly better than the cushioning performance of conventional inner shells of foamed plastic materials, such as polystyrol.

It is basically possible to fasten the pads individually to the outer shell (for instance by means of an adhesive). A particularly advantageous embodiment of the invention is, however, characterised in that the inner layer has at least two carrier sections, on each of which a plurality of pads are arranged. In particular, it is regarded as advantageous if the carrier sections have a carrier layer, which is of flat, preferably flat sheet, construction. It is desirable that the carrier material has a certain stiffness.

The carrier sections have advantages as regards manufacturing technology and also structural technology. On the one hand, by virtue of the carrier sections a plurality of pads can be manufactured simultaneously. On the other hand, the inner layer can be produced advantageously from the structural technical point of view particularly simply by the arrangement of (previously cut to size) carrier sections. Furthermore, the necessary concavity of the inner layer is formed particularly advantageously by a plurality of carrier sections.

Many variants are possible for the specific, structural embodiment of a carrier section. The carrier section preferably has a flat carrier layer and an upper layer constituting the pads. The upper layer is secured by adhesive or welded to the carrier layer. Alternatively, individual (optionally closed) pads are formed, which are attached, particularly secured by adhesive, to the carrier layer.

In order to form the inner layer, a plurality of carrier sections are conveniently connected together. It can advantageously be provided that a space is defined between the carrier sections. This space ensures an additional ventilation of the protective helmet, particularly if spaces or openings are also provided in the outer shell, as will be described in more detail below.

The carrier sections can be directly connected together, for instance in a non-positive manner (e.g. by adhesive) and/or in a positive manner (e.g. by rivets or the like). A positive connection offers the advantage of simple, precise alignment of the carrier sections with respect to one another. The carrier sections are, for instance, clipped into one another. A rivet connection is also regarded as advantageous. A screw connection is also possible. It offers the advantage of releasability. In a particularly preferred construction, the carrier sections are directly connected to the outer shell. The connection of the carrier sections on the outer shell can also provide the connection of the carrier sections to one another.

The inner layer consists, for instance, of three carrier sections, which are connected together. If it is advantageously provided that a space is defined between the carrier sections in the regions, it is also regarded as convenient if at least one carrier section defines at least one convexity, which is preferably occupied, at least partially, by a pad, and that the convexity engages into a concavity in an adjacent carrier section. Two carrier sections thus define a type of interlock, which not only increases the stability of the inner layer but is also responsible for an increase in the pad density, that is to say if the convexity is occupied at least partially by a pad.

It can additionally or alternatively be provided that two adjacent carrier sections overlap in at least one section. The overlap preferably occurs in the region of the convexity/concavity of adjoining carrier sections. The overlap provides a (yet) more stable construction of the inner layer.

Reference was made above to the ventilation of the protective helmet in accordance with the invention, which ensures good wearing comfort. Alternatively or additionally to the proposed gap between the carrier sections, it can be provided that the inner layer has a plurality of openings. It can be provided, in particular, that the carrier section has a plurality of openings. The openings serve as air openings and are preferably arranged between the pads.

In an important embodiment of the invention, it is proposed that arranged between the inner layer and the outer shell there is a functional and/or decorative layer. The functional and/or decorative layer is used, in particular, if the outer shell has a plurality of openings, particularly more than 10 openings, as is considered to be preferred.

The plurality of openings primarily provide an adequate ventilation of the protective helmet. Furthermore, they have the advantage of a considerable saving in material and weight.

In connection with the functional and/or decorative layer, the advantageous embodiment of the helmet in accordance with the invention further provides a completely new helmet concept. The functional and/or decorative layer is preferably a textile layer. As a result of the functional and/or decorative layer, it is possible to impart different overall impressions to the helmet by different decorations. The functional and/or decorative layer can have not only different decorations (patterns) but, for instance, can also be of differing thickness, for instance for the purpose of adapting to the seasons. For instance, a thick wool or fur layer is possible for the winter and a light fabric layer for the summer. The functional and/or decorative layer is visible through the openings in the outer shell of the protective helmet, whereby a matching of the size and numbers of the openings must be effected having regard to the safety of the helmet. The functional and/or decorative layer is preferably arranged directly behind the outer shell. The functional and/or decorative layer is thus particularly easily visible with an overall slim helmet structure.

It is basically provided in the context of the invention that the inner layer provided with pads inherently provides the impact damping of the helmet. The functional and/or decorative layer, on the other hand, selectively has the function of the optical appearance of the protective helmet (in conjunction with the openings in the outer shell), thermal insulation and moisture protection. In the latter case, it can be, for instance, a coated functional and/or decorative layer.

An advantageous embodiment of the invention is characterised in that the inner layer and the functional and/or decorative layer are fastened to the outer shell, preferably at individual positions. This has the advantage that all three components can be fixed in position with a single connection. The fastening is effected, for instance, by rivets which engage through the outer shell, the functional and/or decorative layer and the inner layer.

In a preferred embodiment, the fastening is releasable. In this connection, a press stud fastener or a screw connection, in particular, are suitable. A releasable connection has the substantial advantage that individual components of the helmet in accordance with the invention can be replaced, for instance in the event of wear.

It is considered particularly advantageous if the functional and/or decorative layer is replaceable. The wearer of the helmet can thus conveniently replace the functional and/or decorative layer itself, as required. Thus it is possible that the owner of a helmet has a number of functional and/or decorative layers and selects a particular functional and/or decorative layer and fits it to the helmet in accordance with requirements.

For the safety of the protective helmet in accordance with the invention it can be sufficient that not all the pads uniformly engage the head of the user. It can instead be provided in an embodiment of the invention that at least two pads have different heights with respect to the outer shell. The different heights ensure that only certain pads engage the head. Some pads, on the other hand, are of shorter construction. They either do not engage with the same pre-load or are spaced from the head, which in turn results in yet better ventilation. Only in the event of a crash, that is to say in the event of loading of the protective helmet, are the shorter pads also fully loaded. Reference is made in this connection to the fact that the definition of the different heights with respect to the outer shell is to be understood as meaning that the pads have different heights when orientated horizontally.

As already indicated above, the carrier section preferably has a flat carrier layer and an upper layer constituting the pads. It can also conveniently be provided, having regard to an increased wearing comfort, that at least the upper layer consists of an air permeable material. Such a material not only engages the head of the user more comfortably and potentially also better, but also produces a further increase in the ventilation. For this purpose, the upper layer can be perforated. It is proposed, in particular, that the upper layer consists of a textile material. Natural or synthetic fibres are equally possible for this. The upper layer is stitched to, welded to or secured by adhesive to the carrier layer.

Protective helmets generally also require a fastening strap or the like to secure the helmet to the head of the helmet wearer. The fastening strap is preferably directly connected to the outer shell. An advantageous embodiment of the protective helmet is characterised in that the fastening strap is secured at the same positions as those to which the inner layer and the functional and/or decorative layer is connected. All the components of the helmet including the fastening strap can be connected to the outer shell and also connected to one another with only one fastening device, such as a rivet, a screw connection or a press stud.

The object is further solved by a carrier section for protective helmets, which is characterised in that a plurality of pads are arranged on the carrier section.

The carrier section preferably has a device for connecting the carrier section to another carrier section. Further advantageous embodiments are characterised in the dependent claims and are described above in connection with the helmet in accordance with the invention.

The invention will be described in more detail below by way of a preferred exemplary embodiment with reference to the attached drawings, in which:

FIG. 1 is a perspective view of a protective helmet in accordance with the invention;

FIG. 2 is an exploded view of the protective helmet of FIG. 1;

FIG. 3 shows a portion of the inner layer of the helmet in accordance with the invention, namely a carrier section, on which the pads are arranged;

FIG. 4 is a schematic view of a second exemplary embodiment of a carrier section in accordance with the invention;

FIG. 5 is a schematic side view of a third exemplary embodiment of a carrier section in accordance with the invention;

FIG. 6 is a schematic plan view of two carrier sections engaging into one another of a fourth exemplary embodiment; and

FIG. 7 is a schematic plan view of two adjacent carrier sections in a fifth exemplary embodiment.

FIG. 1 is a perspective view of an exemplary embodiment of the protective helmet in accordance with the invention. The protective helmet has an outer shell 1. In the illustrated exemplary embodiment, the outer shell 1 is shown to be of braided design type and consists, for instance, of polypropylene. As a result of the braided design, openings 2 are produced, through which a functional and/or decorative layer 3 is visible, as will be explained in more detail in conjunction with FIG. 2.

A fastening strap 4, as is known per se, is designated with the reference numeral 4. The fastening strap 4 is directly connected to the outer shell 1, by means of rivets 5 in the illustrated exemplary embodiment. Reference is made at this point to the fact that instead of a rivet connection, a releasable connection, in particular, for instance a screw connection, may also be considered.

FIG. 2 shows the protective helmet of FIG. 1 in an exploded view. As may clearly be seen, the functional and/or decorative layer 3 is matched to the internal shape of the outer shell. In the assembled state, the functional and/or decorative layer 3 may clearly be seen through the openings 2. The nature of the functional and/or decorative layer can be adapted to different requirements.

This applies not only to the type of material but also to the colour and the decoration, which have a significant influence on the overall impression of the helmet.

The functional and/or decorative layer 3 has two openings 6 on each side. The rivets 5 (or other fastening devices), which are only shown schematically in FIG. 2, pass through these openings and through openings 7 in the outer shell 1. The functional and/or decorative layer 3 further has a positioning device 8. The positioning device 8 engages, in the assembled state of the protective helmet, in the outer shell 1, as is shown in FIG. 1. For this purpose, the positioning device 8 preferably has at least one limb 9 (two limbs 9 in the illustrated example embodiment).

The inner layer is substantially constituted by a plurality of pads 10. A respective plurality of pads 10 are arranged on a carrier section 11, whereby the carrier sections 11 are connected together to form the inner layer. For this purpose, the carrier sections 11 have openings 12, through which the rivets 5 pass. The inner layer, the functional and/or decorative layer 3 and the outer shell 1 can consequently be connected together with the rivets 5. In addition to the openings 12, openings 13 are provided, through which a respective fastening device 14 of the positioning device 8 passes. It will be understood that the connection of the carrier sections can also be effected in a different manner.

The carrier sections 11 need not necessarily be of identical construction. They define between themselves at least one space 15. The space 15 ensures good ventilation of the protective helmet.

FIG. 3 shows a portion of the inner layer of the helmet in accordance with the invention, namely the carrier section 11 whose end is in engagement, as shown in FIG. 2, on which the pads 10 are arranged.

A plurality of pads 10 are arranged on a carrier section 11 within the scope of the inventive concept. The carrier sections 11 are preferably sheet-like and can be cut to size in advance with the pads 10. The pads 10 have a part-spherical shape and are filled with beads.

Reference will be made below to FIGS. 4 to 7, in which further exemplary embodiments of carrier sections with a modified pad shape are shown.

FIG. 4 shows a second exemplary embodiment of a carrier section 16 in accordance with the invention. The carrier section 16 has a plurality of pads 17. Formed between the pads 17 are openings 18, which serve as air passages. The carrier section 16 has devices 19 for connecting the carrier section to another carrier section (not shown). The devices 19 are formed as openings, through which a rivet, a screw, a stud (clips) or the like can pass and thus forms a positive connection with another carrier section (not shown).

FIG. 5 is a side view of a further exemplary embodiment of a carrier section 20 in accordance with the invention. The carrier section 20 has pads 21, 22, which are of truncated pylon shape. The free end of the pads is preferably convex. As may be seen well in the side view, the pads 21 are not as high as the pads 22. This means that in the protective helmet in accordance with the invention only the higher pads 22 engage the head of the wearer or at least engage it with a larger pre-load force. The shorter pads 21 do not engage the head in the normal unloaded wearing position. Only in the event of a crash do these pads 21 come into engagement. Such an advantageous construction with shorter pads 21 and longer pads 22 creates better ventilation.

A flat carrier layer 23, on which either an upper layer 24 is attached, which forms the pads 21, 22, has proved to be satisfactory as the basic structure of the carrier section 20. In order to manufacture the carrier section 20, the pads 21, 22 are filled with beads and the upper layer 24 is subsequently attached to the carrier layer 23, particularly by adhesive, by welding, or, if textiles are used, also by stitching, if required. Alternatively, closed pads 21, 22 are attached to the carrier layer 23.

FIG. 6 shows a further exemplary embodiment of two carrier sections 25, 26 in accordance with the invention. The carrier sections 25, 26 define convexities and concavities, as will be described in more detail in conjunction with FIG. 7. The convexities and the concavities cooperate together such that the convexities on the carrier section 25 engage in the concavities on the carrier section 26 and thus the carrier sections 25 and 26 preferably at least partially overlap with one another. For this purpose, the carrier section 26 has a flat edge 27, which is shown in FIG. 6 with a chain line. The carrier section 25 engages over the carrier section 26 in the region of the edge 27.

FIG. 7 shows two further exemplary embodiments of a carrier section. The upper carrier section 28 has pads 29 (shown schematically). The lower carrier section 30 has pads 31 (shown schematically). The lower carrier section 30 defines concavities 32 and convexities 33. The upper carrier section 28 defines two convexities 34 and one concavity 35. The two carrier sections 28 and 30 may be joined together so that the convexities 34 engage into the concavities 33, which advantageously results in the pads 29 and 31 being arranged with a small spacing from one another. The carrier sections 28, 30 can technically overlap with their edges 36, 37.

The helmet in accordance with the invention has a slim visual appearance on the one hand and, on the other hand, a fit which is improved with respect to known helmets with a high wearing comfort.

List of Reference Numerals  1 Outer shell  2 Openings  3 Functional and/or decorative layer  4 Fastening strap  5 Rivet  6 Openings  7 Openings  8 Positioning device  9 Limb 10 Pad 11 Carrier section 12 Opening 13 Opening 14 Fastening device 15 Space 16 Carrier section 17 Pad 18 Opening 19 Connecting device 20 Carrier section 21 Pad 22 Pad 23 Carrier layer 24 Upper layer 25 Carrier section 26 Carrier section 27 Edge 28 Carrier section 29 Pad 30 Carrier section 31 Pad 32 Convexity 33 Concavity 34 Convexity 35 Concavity 36 Edge 37 Edge 

1. A protective helmet including an outer shell, and an inner layer characterised in that the inner layer includes a plurality of pads.
 2. A protective helmet as claimed in claim 1, characterised in that the inner layer includes at least 10 pads, particularly at least 15 pads.
 3. A protective helmet as claimed in claim 1, characterised in that the inner layer includes at least two carrier sections, on each of which a plurality of pads are preferably arranged.
 4. A protective helmet as claimed in claim 3, characterised in that the carrier sections are connected together.
 5. A protective helmet as claimed in claim 4, characterised in that the carrier sections are positively connected together.
 6. A protective helmet as claimed in claim 3, characterised in that a space is formed between the carrier sections.
 7. A protective helmet as claimed in claim 3, characterised in that at least one carrier section defines a convexity, which is occupied, at least in part, by a pad and that the convexity engages into a concavity in an adjacent carrier section.
 8. A protective helmet as claimed in claim 3, characterised in that two adjacent carriers sections overlap in at least one section.
 9. A protective helmet as claimed in claim 3, characterised in that the carrier sections have a plurality of openings.
 10. A protective helmet as claimed in claim 3, characterised in that the carrier sections are directed connected to the outer shell.
 11. A protective helmet as claimed in claim 1, characterised in that arranged between the inner layer and the outer shell there is a functional and/or decorative layer.
 12. A protective helmet as claimed in claim 11, characterised in that the inner layer and/or the functional and/or decorative layer are secured to the outer shell, preferably at individual positions.
 13. A protective helmet as claimed in claim 12, characterised in that the fastening is effected by rivets or is preferably releasable.
 14. A protective helmet as claimed in claim 11, characterised in that the functional and/or decorative layer is replaceable.
 15. A protective helmet as claimed in claim 1, characterised in that at least two pads have different heights with respect to the outer shell.
 16. A protective helmet as claimed in claim 1, characterised in that the carrier section includes a flat carrier layer and an upper layer constituting the pads wherein preferably at least the upper layer includes an air permeable material.
 17. A protective helmet as claimed in claim 1, characterised in that a fastening strap, which is directly connected to the outer shell, and is preferably connected at the same positions as those at which the inner layer and the functional and/or decorative layer are fastened.
 18. A carrier section for protective helmets, characterised in that a plurality of pads are arranged on the carrier section.
 19. A carrier section as claimed in claim 18, characterised in that the carrier section includes at least one device for connecting the carrier section to another carrier section.
 20. A carrier section as claimed in claim 18, characterised in that the carrier section defines at least one convexity, which is preferably occupied, at least partially, by a pad and is advantageously matched to the shape of the pad.
 21. A carrier section as claimed in claim 18, characterised in that the carrier section includes a flat edge, at least in part.
 22. A carrier section as claimed in claim 18, characterised by a plurality of openings.
 23. A carrier section as claimed in claim 18, characterised in that the pads are of different heights.
 24. A carrier section as claimed in claim 18, characterised in that the carrier section includes a flat carrier layer and an upper layer constituting the pads, wherein preferably at least the upper layer includes an air permeable material.
 25. A pad insert with at least two carrier sections as claimed in claim 18, characterised in that the carrier sections are so connected together that they constitute a three-dimensional body. 